VOL: MA-GP2000-2

Troubleshooting GP-2000
Technical Knowledge

GP-2000 : Trouble Shooting

Cause of problems
1: Problems related to other factors
2: Problems on the pressure reducing valve
A : Reduced pressure exceed specified set pressure.
B : Reduced pressure does not reach the set pressure.
C : Unstable operation

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Problems caused by other factors Outlet pressure increase / decrease

Fact example

Problem
Pressure gauge is broken

Solutions
Replace the pressure gauge

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Problems caused by other factors Outlet pressure increase

Fact example

Outlet pressure increase

Problem
By-pass valve has leakage

Solutions
Replace isolation valve

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Problems caused by other factors does not reach the set pressure
Fact example

Rising pipe at outlet side without trap

Solutions
Problem
Condensate at outlet side

Condensate

Decrease the size of piping

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Problems caused by other factors does not reach the set pressure
Fact example
Conditions:
*Inlet : 0.5MPa, pipe size 50A
Outlet : 0.2MPa, pipe size 50A
Steam capacity : 600 kg/h

Problem
Pipe size at outlet side is too small !!
*0.5MPa Pipe size 50A, Velocity : 35.6 m/s
*0.2MPa Pipe size 50A, Velocity : 130 m/s

Solutions
Velocity : 20 40 m/s

50A

65A
Bigger size

High velocity leads to have pressure loss

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Problems caused by other factors does not reach the set pressure
Fact example
Conditions:
*Decrease in outlet pressure
Globe
Valve

Problem
The pressure loss is caused by Globe valve.

The flow capacity of globe valve was cannot

handle the steam capacity.

*Globe valve is installed after PRV

Solutions
*Should install gate valve which has less
pressure loss comparing to globe valve.
*Select proper size of valve after PRV.

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Problems caused by other factors does not reach the set pressure
Fact example
Condensate in the piping and
bottom diaphragm case

Problem
*The pressure at bottom diaphragm cannot
increase because of condensate.

Solutions
*Discharge condensate by opening the
plug at bottom diaphragm case.

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To avoid Scale problem

Proposal : When scale problem
Make sure the strainer is installed before PRV

Screen 60-100 mesh are recommended when installing in front of PRV

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To avoid Scale problem

Proposal : When scale problem

Flushing is required when

Change of piping system
Modifying the piping
installing new piping

Existing piping
-Scales or corrosion exist

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To avoid Water hammer

Proposal : Installing separator and steam trap

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To avoid Water hammer

Proposal : Installing slow start-up station
Slow start-up station prevents water hammer automatically when starting the system.

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GP-2000 : Trouble Shooting

Problem related to product

A. Reduced pressure exceed specified set pressure.

Maintenance procedure
Case 1-A : Check if Orifice B at Tee is clogged?

Case 2-A : Check if foreign material stuck and scratch at pilot valve or seat.
Case 3-A : Check if foreign material stuck and scratch at main valve and valve seat.
Case 4-A : Check if Pilot diaphragm is damaged?
Case 5-A : Check if External sensing pipe is not installed?
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Case 1-A : Check if Orifice B at Tee is clogged?

Phenomenon

Problem

Clogging orifice B by scales causes high

pressure to bottom diaphragm case, and
pressure at diaphragm case stays and cannot
release from Orifice B.

TEE

Clogging orifice B caused by the

collection of scales at the bottom
diaphragm case because of
accumulation of condensate.

Solutions

Orifice A
Clogged

1: Check the existence of

condensate at the bottom
diaphragm case by opening plug at
the bottom diaphragm case.

Orifice B

Orifice C

Pressure

2: Concerning the condensate,

please check if steam trap and
separator is installed or not.
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Case 2-A : Check if foreign material stuck and scratch at pilot valve or seat.

Phenomenon
Increase in outlet pressure!!
because pilot valve force to open by scale

Problem

Solutions

Leakage because valve cannot close completely

Have to change pilot assembly

Parts kit no.
KS-92110

Size

Consists of
Pilot valve assembly
15A-200A Pilot valve gasket
Pilot diaphragm

Q'ty
1
1
2

Pilot valve
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Case 3-A : Check if foreign material stuck and scratch at main valve and valve seat.

Phenomenon
Increase in outlet pressure!!
because main valve tends to open by scales

Solutions
Problem
Leakage because valve cannot close completely

Main valve

Valve seat

Lapping procedure is required

Parts kit no.
Size
KS-92100
15A
KS-92101
20A
KS-92102
25A
KS-92103
32A
KS-92104
40A
KS-92105
50A
KS-92106
65A
KS-92107
80A
KS-92108
100-125A
KS-92109
150A-200A

Consists of
Main valve
Top body gasket
Bottom body gasket
Main valve spring
Spacer gasket*
*For size 50A-125A

Q'ty
1
1
1
1
1

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Case 3-A : Check if foreign material stuck and scratch at main valve or seat.

Solution : Lapping procedure

Step 1) Put lapping powder to the valve seating surface.
Recommended lapping powder: Fujimi incorp. Green silicon carbide
#2000 or #4000. Please mix together with green silicon carbide or oil
before usage.
Step 2) Set the main valve to the valve seat.
Step 3) -a: Turn the main valve clockwise and counterclockwise. Pressing
the main valve down slightly.
-b: Change the main valve position and repeat above procedure.
Step 4) Continue lapping until the main valve and valve seat fit tightly.
(Time for lapping differs in main valve and valve seat condition.)
Step 5) Wipe out lapping powder completely on main valve and valve seat by
soft cloth.
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Case 2 / 3 -A : Check if foreign material stuck and scratch at GP-2000

Inspection method : Steam leakage of GP-2000

Adjusting screw

Step 1 : loosen lock nut of adjusting

screw and loosen screw until feel the
load has been removed.

Step 2 : Loosen joint A & B and slowly

open stop valve a little. Inspect whether
steam leaks out of joint A & B.
Ball valve

By-pass

Pressure
gauge

Pressure
gauge

Safety valve

Strainer

Reducer

Stop
valve
Stop
valve
Blow

Joint B

Stop
valve

Drain
separator

Stop
valve

Joint A

Reducer

Stop
valve

GP-2000

Steam Flow
indicator
Trap

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Case 2 / 3 -A : Check if foreign material stuck and scratch at GP-2000

Inspection method : Steam leakage of GP-2000

Case A : If steam leaks out of joint A,
there may be foreign materials
between the pilot valve & seat.

Problem
area

Case B : If steam leaks out of joint B,

there may be foreign materials
between the main valve & seat.

Steam
Steam

Steam
Problem
area

Steam

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Case 4-A : Check if pilot diaphragm is damaged.

Phenomenon
Pilot diaphragm

Cannot decrease into set pressure!

because of broken pilot diaphragm

Problem

Solutions

Pilot valve always opens because the

pressure at bottom pilot diaphragm cannot
push up diaphragm to adjust into the set
pressure.

Have to change pilot diaphragm

accordance with the procedure

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Case 4-A : Check if pilot diaphragm is damaged.

Procedure of changing pilot diaphragm

Step 1: Prepare a new pilot diaphragm.

(Using spare parts kit described on page 7).
Step 2: Apply liquid sealant to the periphery of the bottom
sealing surface of pilot diaphragm.
(NEVER-SEEZ standard grade, made by BOSTIC is
recommended as a liquid sealant).
Regular Grade Anti Seize
The "original" anti-seize compound and extreme pressure lubricant
formulated with copper, graphite, aluminum and other ingredients to protect
metal parts against rust, corrosion and seizure up to 1800F. Fine metallic
and graphite particles in special grease protect parts even in high heat, high
pressure and corrosive environments. Ford ESE-M12A4-A, Garrett Engine
Div. PCS5724, Pratt & Whitney PWA 360523-2 and tested to MIL-A-907.
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Case 5-A : Check if External sensing pipe is installed?

Phenomenon
Installing without external sensing pipe

Solutions
Install the external sensing pip.

Problem
Without external sensing pipe, the pilot valve
keeps opening by the adjusting spring force.
Pilot valve will not sense and adjust the
reducing pressure.

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Fact Example: Reduced pressure exceed specified set pressure.

Fact example
Installing rising gradient

Problem
Because of accumulation of condensate at
pilot, the pressure transmission to bottom
pilot diaphragm is cut off.

Installed in round shape

Solutions
Install the external sensing pipe in down
slope position not to have accumulation of
condensate.

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Fact Example: Reduced pressure exceed specified set pressure.

Fact example
Conditions:
Piping Drawing

*Mixing valve is only used

once a day.
*Outlet pressure: 0.3MPa

30M
Mixing
Valve

Problem
*Outlet pressure increases up to 0.4MPa after 24 hours, and safety valve blows.
*Accumulation of condensate is cause because of not using for a long period of time.
*Water back flow in the piping system. *Scales stuck at the PRV.

Solutions
*Installing check valve solved the problem, and install trap close to PRV.
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GP-2000 : Trouble Shooting

Problem related to product

B. Pressure does not reach the set pressure.

Maintenance procedure
Case 1-B : Check if Pilot valve assembly is stuck with dirt?
Case 2-B : Check if main diaphragm is damaged?

Case 3-B : Check if Screen is clogged?

Case 4-B : Check if Orifice C at Tee is clogged?
Case 5-B : Check if External sensing pipe is clogged?
Case 6-B : Check if Nominal size is too small for the steam capacity?
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Case 1-B : Check if pilot valve assembly is stuck with dirt?

Phenomenon
Outlet pressure cannot control!!
because defect on pilot valve

Problem
Leakage will be caused and valve cannot open completely because of dirt.

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Case 1-B : Check if pilot valve assembly is stuck with dirt?

Inspection method
Step 1 : Turn the pilot valve assembly
upside down and place it on a table.

Solutions
Change the parts as pilot assembly

Step 2 : Hold valve seat by fingers, depress

the assembly strongly and check
whether valve seat moves.

Pilot assembly
Parts kit no.
KS-92110

Size

Consists of
Pilot valve assembly
15A-200A Pilot valve gasket
Pilot diaphragm

Q'ty
1
1
2

*Please also change pilot diaphragm at the

same time.

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Case 2-B : Check if main diaphragm is damaged?

Phenomenon
1: With broken diaphragm, the pressure
cannot push up the diaphragm because
the pressure runs through the diaphragm.

2: Diaphragm cannot push up the main valve

via retainer and spindle

Problem

1: Scale problem
-Scales go into diaphragm case

2: Water hammer
-On-off valve or too much
condensate in the piping system

3: Outlet pressure will be Zero.

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Case 2-B : Check if main diaphragm is damaged?

Solution by Modification
1: Scale problem

Scale moves into

diaphragm case

Equalizing line

*Please make sure strainer (60 80

mesh) is installed before PRV.
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Case 2-B : Check if main diaphragm is damaged?

Proposal : to avoid water hammer
2: Water hammer

. On-off valve should be installed in front of PRV

. Proper location (more than 3M away from PRV)

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Case 3-B : Check if screen is clogged?

Phenomenon

*Steam cannot flow because the integral

strainer is clogged

Problem
Steam cannot go through strainer
because of too much scales

Solutions
Clean up or change the integral strainer

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Case 4-B : Check if Orifice C at Tee is clogged?

Phenomenon
Orifice A

Clogged

TEE

Orifice B
Orifice C

Problem
Steam cannot flow to the bottom
diaphragm case and cannot push up
the diaphragm to lift up the main valve

Solutions
Blow inside of the tee with compressed air.

Pressure does not reach the set pressure

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Case 5-B : Check if external sensing pipe is clogged?

Phenomenon
Clogged

Problem

Lots of scales inside of the piping

The pressure inside of external sensing pipe

cannot escape because of scales,

Solutions
Blow inside of the external sensing pipe with
compressed air.

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Case 6-B : Check if Nominal size is too small for the steam capacity

Fact example

Too much steam capacity to PRV

Large steam capacity

Velocity

Reduced Pressure

Problem

Solutions
*Select proper size of PRV
*Steam velocity should be 20 to 40 m/s

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Fact Example: Pressure does not reach the set pressure.

Fact example
Installing wrong side up

Installing normal position

Orifice C

Orifice A (5mm)
Orifice B (4mm)

Orifice B

Orifice C (3mm)

Problem

Required pressure cannot flow to bottom

diaphragm, and diaphragm does not move to
open main valve

Orifice A

Solutions

Assemble with right position

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GP-2000 : Trouble Shooting

Problem related to product

C. Unstable operation
Maintenance procedure
Case 1-C : Pressure reduction ratio is too big
Case 2-C : Nominal size is too large

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Problems caused by other factors Unstable operation

Fact example

Problem
*Pressure reduction ratio is 40 : 1

Inlet pressure
2.0MPa

Outlet pressure

*Reduction ratio must be less than 20 : 1

0.05MPa

Solutions
Two-stage reduction

3M or more

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Problems caused by other factors Unstable operation

Fact example

Tank

Vibration problem

Conditions:
*Flow rate: 30 kg/h
*GP-2000 25A & OB-30 25A
*P1: 0.4MPa, P2: 0.2MPa
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Problems caused by other factors Unstable operation

Vibration is caused because

*Rated flow of GP-2000 : 600kg/h and
Flow rate : 30kg/h is only 5% of rated flow.
*When the flow becomes lower than 30 kg/h
vibration is occurred.

Reduced Pressure

Problem

Solutions
*Should install proper size of PRV.
*Installing GP-1000 15A or GD-30 15A to solve the problem.
*Select proper size of the valve between
30 to 80 % of rated flow.

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